FUNCTIONAL AND DURABLE THERMOELECTRIC DEVICES AND SYSTEMS
The present disclosure provides a thermoelectric device comprising a panel comprising an electrically and thermally insulating material, and a thermoelectric string comprising a plurality of thermoelectric elements mounted on a strain relief element within the panel. The thermoelectric elements may comprise an n-type thermoelectric element and a p-type thermoelectric element electrically coupled to one another in series. The thermoelectric string may be (i) compacted in cross section inside the panel and (ii) expanded in cross section outside the panel. The strain relief element may permit the thermoelectric string to be movable in proximity to the strain relief element.
This application claims priority to U.S. Provisional Application Ser. No. 62/076,042, filed Nov. 6, 2014, U.S. Provisional Application Ser. No. 62/133,215, filed Mar. 13, 2015, U.S. Provisional Application Ser. No. 62/172,751, filed Jun. 8, 2015, and U.S. Provisional Application Ser. No. 62/191,207, filed Jul. 10, 2015, each of which is entirely incorporated herein by reference.
BACKGROUNDThe thermoelectric effect is the conversion of temperature differences to electric voltage and vice versa. A thermoelectric device may create voltage when there is a temperature gradient across the thermoelectric device, such as when there is a different temperature on each side of the thermoelectric device. Conversely, when a voltage is applied to the thermoelectric device, it may create a temperature difference. An applied temperature gradient may cause charge carriers in the thermoelectric device to diffuse from a hot side to a cold side of the thermoelectric device.
The term “thermoelectric effect” encompasses the Seebeck effect, Peltier effect and Thomson effect. Solid-state cooling and power generation based on thermoelectric effects typically employ the Seebeck effect or Peltier effect for power generation and heat pumping. The utility of such conventional thermoelectric devices is, however, typically limited by their low coefficient-of-performance (COP) (for refrigeration applications) or low efficiency (for power generation applications).
Thermoelectric modules may contain densely packed elements spaced apart by 1-3 mm. Up to 256 such elements may be connected in an array that is 2×2 inches (5.08×5.08 cm) in area. When these modules are deployed, large and heavy heat sinks and powerful fans may be required to dissipate or absorb heat on each side. Small elements with low resistance may allow larger current (I) to flow before the resistive heat (I2R) generated destroys the thermoelectric cooling. The use of short elements for maximum cooling capacity results in the hot and cold side circuit boards being close together. This proximity may result in the high density.
To achieve low density packing of thermoelectric elements, the elements may be laterally spaced on the boards, but then the backflow of heat conducted and radiated through the air between the elements limits the overall performance. Some designs may require evacuating the module interior to reduce heat backflow due to air conduction, but vacuum cavities require expensive materials and are prone to leaks. Vacuum materials (like glass and Kovar™) are also hard and easily broken when thin enough to limit their own backflow of heat. Broken glass can lead to safety issues when these modules are used in seat cushions, automobiles, and other environments.
Another problem in spreading out thermoelectric elements is that the rigid connection of elements over large distances causes them to rupture due to sheer stress upon thermal expansion of the hot side relative to the cold side. To solve this problem, other designs have been proposed that use a flexible plastic such as polyimide for the circuit boards, but these materials are too porous to maintain a vacuum.
Another disadvantage of the prior art design of thermoelectric modules is that the high density of heat moved to the hot side may result in a temperature gradient through the heat sink, and this temperature change may subtract from the overall cooling that the module can achieve. In particular, traditional thermoelectric products may not be able to reach true refrigeration temperature because of this temperature gradient.
In addition, because some traditional thermoelectric modules may be placed in a solder reflow oven during assembly, only high-temperature materials may be used. Unfortunately, many desired uses of cooling and heating involve close or direct contact with the human body, for which soft materials, such as cushions, cloths, and flexible foam may be preferred, but these materials cannot withstand the high temperatures of a solder reflow oven.
SUMMARYThermoelectric devices can be as efficient, or even more efficient, than vapor compression cooling systems when the temperature change is 10° C. or less. The total energy savings of the central A/C or heating system plus the local thermoelectric systems can be 30% or more for such a combination, but the unwieldy implementation of some traditional thermoelectric modules inhibits their use for this purpose. As such, recognized herein is the need to deploy thermoelectric technology for local heating and cooling of occupied spaces and thereby reduce the overall energy consumption needed for such deployment, as well as the need for a variety of insulating panels to be safely and comfortably improved with thermoelectric capability, such as seat cushions (e.g., car seat, truck seat, boat seat, or airplane seat), mattresses, pillows, blankets, ceiling tiles, office/residence walls or partitions, under-desk panels, electronic enclosures, building walls, solar panels, refrigerator walls, freezer walls within refrigerators, or crisper walls within refrigerators. In addition, because thermoelectric modules may be used for power generation, recognized herein is the need for a low-cost electrical power generation capability that can supply power 24 hours per day, 7 days per week, and 365 days per year and only tap renewable energy sources.
The present disclosure provides thermoelectric modules comprising thermoelectric strings, which may be used to transfer heat to or from objects. When connected together, thermoelectric strings may be assembled in an array formation.
The present disclosure provides methods of producing thermoelectric strings and integrating thermoelectric strings within consumer products. Additionally, designs of thermoelectric strings and devices that include one or more thermoelectric strings are provided.
The present disclosure describes advancements to a connected series of thermoelectric strings, such as thermoelectric panels, that improves durability; advancements in the integration of the thermoelectric strings and/or thermoelectric panels with surfaces that improve smoothness and softness of a consumer product; and advancements in air flow systems that improve manufacturability and thermal performance of thermoelectric strings and/or thermoelectric panels. Thermoelectric strings and thermoelectric panels as discussed herein may be used in many products and applications, such as seats, seat backs, seat tops, beds, bed tops, wheelchair cushions, hospital beds, animal beds, and office chairs.
The present disclosure also provides examples of a T-shaped (or substantially T-shaped) configuration of a thermoelectric string. While some examples of thermoelectric strings may be bent when inserted into a desired material to be heated and/or cooled, examples discussed herein provide links of the thermoelectric string that may be connected to a strain relief at a 45 degree to 90-degree angle. By connecting the links of the thermoelectric string to the strain relief at a 45 degree to 90-degree angle rather than bending the links, embodiments described herein lessen and/or eliminate the need for the wires to be bent at varying degrees. Additionally, minimizing the bending of the wires of the links may be used to improve the durability and the thermoelectric string.
Additionally, the disclosure also provides examples of different materials that may be placed between links of a thermoelectric string and a surface of a seat, bed, or other product. In some examples, materials that may be placed between links of a thermoelectric string may be used to improve the smoothness or softness or both smoothness and softness of the feel of the surface while also maintaining adequate thermal transmission. Examples of materials that may be placed between links of a thermoelectric string include polyester fill material, rubber material, lamb's wool, corrugated textiles, and non-slip pads.
In additional embodiments, air flow systems are provided that allow for easy integration of thermoelectric strings with product manufacturing processes. Additionally, air flow systems may also be used to accommodate moving parts of products, such as a seat cushion or a bed. In some examples, a flexible and sealed spacer mesh duct may be combined with linear air channels to provide an air path to the underside of a seat or bed cushion or the backside of a seatback cushion. In additional examples, a foam material may be used for an air duct, allowing for flexibility and noise abatement. In further examples, flexible tubing may be used to reach movable portions of a seat cushion, including a thigh support area that may move forward and backward. Flexible tubing may also be used to reach side-bolster support areas that may move inward and outward.
An aspect of the present disclosure provides a thermoelectric device, comprising a panel comprising an electrically and thermally insulating material; and a thermoelectric string comprising a plurality of thermoelectric elements mounted on a strain relief element within the panel, wherein the thermoelectric elements comprise an n-type thermoelectric element and a p-type thermoelectric element electrically coupled to one another in series, wherein the thermoelectric string is (i) compacted in cross section inside the panel and (ii) expanded in cross section outside the panel, and wherein the strain relief element permits the thermoelectric string to be movable in proximity to the strain relief element.
In some embodiments, the thermoelectric string is secured to the panel in the absence of an adhesive.
In some embodiments, the thermoelectric device further comprises an additional strain relief element within the panel, wherein the thermoelectric string is mounted on the additional strain relief element. In some embodiments, the thermoelectric string is threaded into the additional strain relief element through an opening to permit the thermoelectric string to rotate with respect to the additional strain relief element. In some embodiments, the thermoelectric device further comprises a plurality of additional thermoelectric elements mounted on the additional strain relief element, wherein the additional thermoelectric elements comprise an n-type thermoelectric element and a p-type thermoelectric element electrically coupled to one another in series, and wherein the additional thermoelectric elements are in electrical communication with the plurality of thermoelectric elements mounted on the strain relief panel.
In some embodiments, the n-type thermoelectric element is electrically coupled to the p-type thermoelectric element through a stranded wire in the panel. In some embodiments, the strain relief element is removable from the panel.
In some embodiments, the panel is elongated. In some embodiments, the thermoelectric string comprises stranded wires with opposing ends that are each terminated by a termination element to maintain compaction of the stranded wires. In some embodiments, the opposing ends are terminated with ferrule or splice bands. In some embodiments, the stranded wires are attached to the plurality of thermoelectric elements and/or the strain relief element with solder.
In some embodiments, the thermoelectric string is threaded into the strain relief element through an opening in the strain relief element, which opening permits the thermoelectric string to rotate with respect to the strain relief element. In some embodiments, the strain relief element comprises glass fiber, epoxy, and/or composite material.
In some embodiments, the thermoelectric device further comprises an intermediate pad adjacent to the panel and a cover adjacent to the intermediate pad. In some embodiments, the intermediate pad has an uncompressed thickness between about 5 millimeters and 10 millimeters. In some embodiments, the intermediate pad comprises viscoelastic foam, polyester fibers and/or carbon particles. In some embodiments, the carbon particles are diamond particles. In some embodiments, the intermediate pad is a flexible embossed sheet. In some embodiments, the flexible embossed sheet comprises rubber, neoprene, urethane, and/or silicone. In some embodiments, centers of the flexible embossed sheet are separated by a distance between about 3 millimeters and 10 millimeters. In some embodiments, the intermediate pad is formed of wool. In some embodiments, the intermediate pad is comprised of a textile sheet with pre-stretched elastic fibers. In some embodiments, the intermediate pad is comprised of a lattice with walls and voids. In some embodiments, the voids are square or square-like with side lengths between about 3 millimeters and 10 millimeters. In some embodiments, the thermoelectric device further comprises an additional layer between the intermediate layer and the cover, wherein the additional layer permits the cover to move relative to the intermediate layer.
In some embodiments, the strain relief element is disposed in a trench among a plurality of trenches in the panel. In some embodiments, each of the plurality of trenches has a cross-section that is circular, triangular, semicircular, square or rectangular.
In some embodiments, the strain relief element is disposed in a linear slit among a plurality of slits in the panel. In some embodiments, the linear slit is at an acute or right angle relative to a surface of the panel.
In some embodiments, the thermoelectric device further comprises a fluid flow system comprising channels adjacent to the panel. In some embodiments, the thermoelectric device further comprises a bagged and flexible spacer mesh for routing a fluid to the channels. In some embodiments, the thermoelectric device further comprises a fan at an end of the bagged and flexible spacer mesh. In some embodiments, the fluid flow system is mounted below or behind a set. In some embodiments, the thermoelectric device further comprises a foam tube in fluid communication with the channels. In some embodiments, the thermoelectric device further comprises a plurality of thermoelectric strings including the thermoelectric string in the channels, which plurality of thermoelectric strings includes wires spread out on a surface of the panel.
In some embodiments, the thermoelectric device further comprises a plurality of thermoelectric strings including the thermoelectric string, wherein each of the plurality of thermoelectric strings comprises a plurality of thermoelectric elements mounted on a given strain relief element within the panel.
In some embodiments, the panel comprises holes that are directed from a first side of the panel to a second side of the panel, wherein the second side is adjacent to an air flow layer, wherein the holes permit a fluid to flow from the first side to the second side to mix with air in the air flow layer.
Another aspect of the present disclosure provides a thermoelectric system comprising one or more thermoelectric devices as described above or elsewhere herein.
Another aspect of the present disclosure provides method for forming a thermoelectric device or system as described above or elsewhere herein. In some embodiments, a method for forming a thermoelectric device or system comprises (a) generating a trench or linear slit in a panel comprising an electrically and thermally insulating material; and (b) providing a thermoelectric string comprising a plurality of thermoelectric elements mounted on a strain relief element within the trench or linear slit, wherein the thermoelectric elements comprise an n-type thermoelectric element and a p-type thermoelectric element electrically coupled to one another in series, wherein the thermoelectric string is (i) compacted in cross section inside the panel and (ii) expanded in cross section outside the panel, and wherein the strain relief element permits the thermoelectric string to be movable in proximity to the strain relief element.
In some embodiments, (b) comprises securing the thermoelectric string to the panel without the use of an adhesive. In some embodiments, (a) comprises generating a plurality of trenches or linear slits in the panel, which plurality of trenches or linear slits includes the trench or linear slit. In some embodiments, (b) comprises providing a plurality of thermoelectric strings including the thermoelectric string, wherein each of the plurality of thermoelectric strings comprises a plurality of thermoelectric elements mounted on a given strain relief element within the panel.
In some embodiments, the method further comprises (i) providing an intermediate pad adjacent to the panel, and (ii) providing a cover adjacent to the intermediate pad. In some embodiments, (b) comprises (i) mounting the thermoelectric elements on the strain relief element and (ii) inserting the strain relief element in the panel.
In some embodiments, (a) comprises removing a select portion of the panel to generate the trench or linear slit, and (b) comprises providing a portion of the thermoelectric string in the trench or panel. In some embodiments, the method further comprises replacing the selection portion over the portion of the thermoelectric string provided in the trench or linear slit.
Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
INCORPORATION BY REFERENCEAll publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings (also “figure” and “FIG.” herein), of which:
While various embodiments of the invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed.
The term “adjacent” or “adjacent to,” as used herein, includes ‘next to’, ‘adjoining’, ‘in contact with’, and ‘in proximity to’. In some instances, adjacent components are separated from one another by one or more intervening layers. The one or more intervening layers may have a thickness less than about 10 millimeters (mm), 5 mm, 1 mm, 0.5 mm, 0.1 mm, 10 micrometers (“microns”), 1 micron, 500 nanometers (“nm”), 100 nm, 50 nm, 10 nm, 1 nm, 0.5 nm or less. Such thickness may be for the one or more intervening layers being in an uncompressed state. For example, a first layer adjacent to a second layer can be in direct contact with the second layer. As another example, a first layer adjacent to a second layer can be separated from the second layer by at least a third layer.
The present disclosure provides methods of producing thermoelectric strings and integrating thermoelectric strings within consumer products, such sitting or sleeping surfaces, including seats and beds. Such seats may be part of vehicles, such as cars, trucks, motorcycles, scooters, boats, airplanes, helicopters, and tanks. The present disclosure also provides configurations of thermoelectric strings and devices that include one or more thermoelectric strings.
Durable Thermoelectric DevicesA thermoelectric string may comprise links that are operatively coupled together within a product. A string may have individual strands, such as at least 2, 3, 4, 5, 6, 7, 8, 9, 10, 20, 30, 40, 50, 100, 200, 300, 400, 500, 1000 or more strands. The strands may be wires.
The thermoelectric string may be inserted into the top layer of a surface, such as a surface of a product, so as to add heating and cooling to that surface. In some examples, the thermoelectric string may comprise links mounted on a strain relief. The thermoelectric strings may have conductors emanating upwards toward the surface to insert or remove heat. Additionally or alternatively, the thermoelectric strings may have conductors emanating downwards to a heat exchanger layer. The conductors may comprise stranded wires, for example, which may allow for expansion of the strands on the surface and/or the heat exchanger. Such expansion may be used to increase the surface area available for conducting heat on the object or person resting on the surface. Additionally, such expansion may increase the surface area for heat exchange via air flow. By not expanding the strands near the strain relief, backflow of heat may be better controlled.
The strain relief (or strain relief element) may be formed of various materials. In some examples, the strain relief is formed of a metallic or insulating material. The strain relief may be formed of a polymeric material or composite material. The composite material may be comprises of woven fiberglass cloth with an epoxy resin binder that may be flame resistant (self-extinguishing), such as FR-4. The strain relief may be formed of circuit board material. In some examples, the strain relief comprises glass fiber or epoxy.
In some examples of thermoelectric string designs, a 45 degree to 90-degree angle may be formed in the conductor as the thermoelectric string reaches the surface. In designs where the conductor is composed of stranded wire, the stranded wire may bend to accommodate this 45 degree to 90-degree angle as the conductor reached the surface. However, as the stranded wire is exposed to stress, the angle of bending may result in a breaking point in the wire. In some examples, stranded wire experience breaks at the angle that they are bent when they are repeatedly exposed to flexing, such as under cyclic stress. Examples of cyclic stress may occur from repeated flexing under cyclic stress by, for example, a person's repeated sitting or lying down on a seat and/or bed that includes a thermoelectric string near the surface.
In contrast to the thermoelectric string designs that have a bending angle as they approach the surface, devices as provided herein include thermoelectric strings having a T-shaped (or substantially T-shaped) design or configuration. In particular, the T-shaped design disclosed herein does not require a wire to be bent at 45 degrees to 90 degrees as the thermoelectric string approaches a surface. Instead, the wire strands may be terminated with a ferrule or splice band. As an alternative, the wire strands may be terminated without a ferrule or splice band. Such termination may be soldered at a 0 degree to 90 degree angle, 10 degree to 90 degree angle, 20 degree to 90 degree angle, 30 degree to 90 degree angle, 40 degree to 90 degree angle, or 45 degree to 90 degree angle relative to the board so as to relieve strain of the circuit board.
Accordingly,
As provided in
The wire strands 105 and 106 may provide for improved heat transfer. In some examples, the wire strands 105 and 106 permit improved heat transfer to or from a fluid (e.g., air) that comes in contact with the wire strands 105 and 106. The wire strands 105 and 106 may be distributed on a surface of a panel, such as an insulating panel.
A thermoelectric string may include alternating p-type 102 and n-Type 103 thermoelectric elements, which may be connected by lengths of braided or stranded wire. The thermoelectric elements may comprise metals, although non-metallic conductors such as graphite and carbon may be used. In some embodiments, the alternating elements can be small crystals of, e.g., Bismuth Telluride (n-type) 103 and, e.g., Antimony Bismuth Telluride (p-type) 102, in some cases plated with, e.g., nickel and/or tin on the ends to facilitate solder connections, or small thermo-tunneling vacuum tubes. Because the thermoelectric elements or tubes may be fragile, the strain relief may prevent a pulling force on the wire from breaking the elements. The aggregate diameter of the stranded or braided wire may be designed to carry the desired electrical current with minimal resistance. Other examples of configurations of thermoelectric strings that may be used with methods, devices and systems of the present disclosure are provided in U.S. Pat. No. 8,969,703 to Makansi et al. (“Distributed thermoelectric string and insulating panel”), which is entirely incorporated herein by reference.
The stranded wires below the strain relief in
In an example, a thermoelectric string is built and durability-tested with a machine simulating the addition and removal of a 160-pound person's weight 100,000 times, and the thermoelectric string is fully functional at the end of the test.
Smoothness and SoftnessThermoelectric devices and systems of the present disclosure can include a panel with thermoelectric strings adjacent to a pad. The pad may be formed of various materials, as described elsewhere herein. The pad may be a thermally and/or electrically insulating panel. In some cases, the pad may be thermally conductive. In some cases, one or more additional layers may be adjacent to the pad, such as, for example, a cover.
In the evaluation of a seat or bed surface, a potential customer may rub a hand along the surface expecting to feel softness and smoothness. The softness and smoothness feel by hand may be related to the buyer's perception of comfort and quality. As such, the automotive and seating industries have often included a “plus pad” underneath the cover, which is a thin, soft foam layer. Even underneath a leather cover, this foam pushes the leather upwards, creating a soft feel when touched or rubbed such as by a potential customer's hand. In addition, this thin soft foam layer may be used to hide irregularities in the firm foam underneath, thereby creating a smoothness feel.
The inclusion of a foam plus pad with a distributed thermoelectric panel diminishes performance because soft foams are very insulating. In view of this, other materials may be used as plus pads. For example, conductive (e.g., graphite) particles may be added to foam that may be used as a plus pad. In other examples, visco-elastic foam, which collapses more than standard foam, may be used as a plus pad. In additional examples, a combination visco-foam with conductive particles may be added to foam, or other materials, that may be used as a plus pad. As such, these materials may increase the thermal conduction of a plus pad while maintaining the soft and smooth feel by hand at the surface over the cover.
Provided herein are several examples of materials that may be used as the plus pad layer just beneath a seat cover. In some examples, the seat cover may be leather. Without limitation, these examples may be applied to products such as beds, office chairs, sofas, easy chairs, auto seats, truck seats, wheelchair cushions, and medical surfaces where it may be desirable for a plus pad to be used to maximize thermal conduction when the surface is occupied.
In some examples, a soft and smooth feel of a product may be accomplished by using a plus pad and that has a large amount of air when not under pressure (e.g., during hand feel), but that also expels a significant amount of air when the plus pad is under the pressure or weight of a body sitting or lying down on the surface. In some examples, a plus pad may expel an amount of air that represents at least 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 98%, 99%, or more than 99% of its volume when the plus pad is in a resting position. However, standard foam does not expel enough of the air under pressure than a similar amount of standard foam, resulting in less thermal conduction. The materials disclosed herein expel more air under pressure, or include other conductive particles or a combination of these, resulting in greater thermal conduction. These materials disclosed herein are tested for thermal intensity when used as a plus pad in a heated and/or cooled seat. These materials are also tested for smoothness and softness during a hand feel. The materials performed better in these tests than standard polyurethane foam or standard viscoelastic foam.
A foam pad may have various thicknesses. In some examples, the foam pad has a thickness from about 0.1 millimeter (mm) to 100 mm, or 1 mm to 50 mm, or 5 mm to 10 mm. Such thickness may be for the foam pad being in an uncompressed state.
Accordingly,
With the apparatus in
Although
Plus pads as illustrated in
This present disclosure also provides fluid flow systems that may carry heat away from the heat exchangers in the thermoelectric string. Such flow systems may be integrated with various media, such as automotive seats. The fluid flow system may direct the flow of a gas, such as air, or other cooling and/or heating fluid, such as a cooling liquid.
In some cases, it is desirable to have some fluid flow (e.g., air flow) laterally just beneath holes in the cover in order to wick away, or evaporate, a fluid on or adjacent to the user when sitting down, such as perspiration. For example,
Without limitation, the thermoelectric string exposed in
Also, without limitation, the insert of
Thermoelectric devices, systems and methods of the present disclosure may be combined with or modified by other thermoelectric devices, systems or methods, such as those described in, for example, U.S. Pat. No. 8,969,703 to Makansi et al. (“Distributed thermoelectric string and insulating panel”), which is entirely incorporated herein by reference.
While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. It is not intended that the invention be limited by the specific examples provided within the specification. While the invention has been described with reference to the aforementioned specification, the descriptions and illustrations of the embodiments herein are not meant to be construed in a limiting sense. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. Furthermore, it shall be understood that all aspects of the invention are not limited to the specific depictions, configurations or relative proportions set forth herein which depend upon a variety of conditions and variables. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is therefore contemplated that the invention shall also cover any such alternatives, modifications, variations or equivalents. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby.
Claims
1. A thermoelectric device, comprising:
- a panel comprising an electrically and thermally insulating material; and
- a thermoelectric string comprising a plurality of thermoelectric elements mounted on a strain relief element within said panel, wherein said thermoelectric elements comprise an n-type thermoelectric element and a p-type thermoelectric element electrically coupled to one another in series, wherein said thermoelectric string is (i) compacted in cross section inside said panel and (ii) expanded in cross section outside said panel, and wherein said strain relief element permits said thermoelectric string to be movable in proximity to said strain relief element.
2. The thermoelectric device of claim 1, wherein said thermoelectric string is secured to said panel in the absence of an adhesive.
3. The thermoelectric device of claim 1, further comprising an additional strain relief element within said panel, wherein said thermoelectric string is mounted on said additional strain relief element.
4. The thermoelectric device of claim 3, wherein said thermoelectric string is threaded into said additional strain relief element through an opening to permit said thermoelectric string to rotate with respect to said additional strain relief element.
5. The thermoelectric device of claim 3, further comprising a plurality of additional thermoelectric elements mounted on said additional strain relief element, wherein said additional thermoelectric elements comprise an n-type thermoelectric element and a p-type thermoelectric element electrically coupled to one another in series, and wherein said additional thermoelectric elements are in electrical communication with said plurality of thermoelectric elements mounted on said strain relief panel.
6. The thermoelectric device of claim 1, wherein said n-type thermoelectric element is electrically coupled to said p-type thermoelectric element through a stranded wire in said panel.
7. (canceled)
8. (canceled)
9. The thermoelectric device of claim 1, wherein said thermoelectric string comprises stranded wires with opposing ends that are each terminated by a termination element to maintain compaction of said stranded wires.
10. (canceled)
11. (canceled)
12. The thermoelectric device of claim 1, wherein said thermoelectric string is threaded into said strain relief element through an opening in said strain relief element, which opening permits said thermoelectric string to rotate with respect to said strain relief element.
13. (canceled)
14. The thermoelectric device of claim 1, further comprising an intermediate pad adjacent to said panel and a cover adjacent to said intermediate pad.
15. The thermoelectric device of claim 14, wherein said intermediate pad has an uncompressed thickness between about 5 millimeters and 10 millimeters.
16. The thermoelectric device of claim 14, wherein said intermediate pad comprises viscoelastic foam, polyester fibers and/or carbon particles.
17. (canceled)
18. The thermoelectric device of claim 14, wherein said intermediate pad is a flexible sheet with centers that are spaced apart from 3 millimeters to 10 millimeters.
19. (canceled)
20. (canceled)
21. (canceled)
22. (canceled)
23. (canceled)
24. (canceled)
25. The thermoelectric device of claim 14, further comprising an additional layer between said intermediate layer and said cover, wherein said additional layer permits said cover to move relative to said intermediate layer.
26. The thermoelectric device of claim 1, wherein said strain relief element is disposed in a trench among a plurality of trenches in said panel.
27. (canceled)
28. The thermoelectric device of claim 1, wherein said strain relief element is disposed in a linear slit among a plurality of slits in said panel.
29. (canceled)
30. The thermoelectric device of claim 1, further comprising a fluid flow system comprising channels adjacent to said panel.
31. (canceled)
32. (canceled)
33. (canceled)
34. (canceled)
35. The thermoelectric device of claim 30, further comprising a plurality of thermoelectric strings including said thermoelectric string in said channels, which plurality of thermoelectric strings includes wires spread out on a surface of said panel.
36. The thermoelectric device of claim 1, further comprising a plurality of thermoelectric strings including said thermoelectric string, wherein each of said plurality of thermoelectric strings comprises a plurality of thermoelectric elements mounted on a given strain relief element within said panel.
37. The thermoelectric device of claim 1, wherein said panel comprises holes that are directed from a first side of said panel to a second side of said panel, wherein said second side is adjacent to an air flow layer, wherein said holes permit a fluid to flow from said first side to said second side to mix with air in said air flow layer.
38. A method for forming a thermoelectric device, comprising:
- (a) generating a trench or linear slit in a panel comprising an electrically and thermally insulating material; and
- (b) providing a thermoelectric string comprising a plurality of thermoelectric elements mounted on a strain relief element within said trench or linear slit, wherein said thermoelectric elements comprise an n-type thermoelectric element and a p-type thermoelectric element electrically coupled to one another in series, wherein said thermoelectric string is (i) compacted in cross section inside said panel and (ii) expanded in cross section outside said panel, and wherein said strain relief element permits said thermoelectric string to be movable in proximity to said strain relief element.
39. The method of claim 38, wherein (b) comprises securing said thermoelectric string to said panel without the use of an adhesive.
40. The method of claim 38, wherein (a) comprises generating a plurality of trenches or linear slits in said panel, which plurality of trenches or linear slits includes said trench or linear slit.
41. The method of claim 38, wherein (b) comprises providing a plurality of thermoelectric strings including said thermoelectric string, wherein each of said plurality of thermoelectric strings comprises a plurality of thermoelectric elements mounted on a given strain relief element within said panel.
42. The method of claim 38, further comprising (i) providing an intermediate pad adjacent to said panel, and (ii) providing a cover adjacent to said intermediate pad.
43. The method of claim 38, wherein (b) comprises (i) mounting said thermoelectric elements on said strain relief element and (ii) inserting said strain relief element in said panel.
44. The method of claim 38, wherein (a) comprises removing a select portion of said panel to generate said trench or linear slit, and (b) comprises providing a portion of said thermoelectric string in said trench or panel.
45. The method of claim 44, further comprising replacing said selection portion over said portion of said thermoelectric string provided in said trench or linear slit.
Type: Application
Filed: Nov 6, 2015
Publication Date: May 12, 2016
Inventors: Tarek Makansi (Tucson, AZ), John Latimer Franklin (Tucson, AZ), Kevin Forbes (Tucson, AZ), Kevin Geisler (Tucson, AZ), Jose Santos Dominguez (Bisbee, AZ), Michael Sato (Tucson, AZ), Robert Fogoros (Green Valley, AZ), Richard Myers (Oro Valley, AZ)
Application Number: 14/934,757